System for radially expanding a tubular member

ABSTRACT

A system for radially expanding a tubular member.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is the National Stage patent application for PCTpatent application serial number PCT/US2003/011765, filed on Apr. 17,2003, which claimed the benefit of the filing dates of (1) U.S.provisional patent application Ser. No. 60/383,917, filed on May 29,2002, the disclosures of which are incorporated herein by reference.

The present application is related to the following: (1) U.S. patentapplication Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patentapplication Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patentapplication Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patentapplication Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patentapplication Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patentapplication Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patentapplication Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patentapplication Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patentapplication Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patentapplication Ser. No. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S.provisional patent application Ser. No. 60/162,671, filed on Nov. 1,1999, (12) U.S. provisional patent application Ser. No. 60/154,047,filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser.No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patentapplication Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S.provisional patent application Ser. No. 60/159,033, filed on Oct. 12,1999, (16) U.S. provisional patent application Ser. No. 60/212,359,filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser.No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patentapplication Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S.provisional patent application Ser. No. 60/221,645, filed on Jul. 28,2000, (20) U.S. provisional patent application Ser. No. 60/233,638,filed on Sep. 18, 2000, (21) U.S. provisional patent application Ser.No. 60/237,334, filed on Oct. 2, 2000, (22) U.S. provisional patentapplication Ser. No. 60/270,007, filed on Feb. 20, 2001, (23) U.S.provisional patent application Ser. No. 60/262,434, filed on Jan. 17,2001, (24) U.S, provisional patent application Ser. No. 60/259,486,filed on Jan. 3, 2001, (25) U.S. provisional patent application Ser. No.60/303,740, filed on Jul. 6. 2001, (26) U.S. provisional patentapplication Ser. No. 60/313,453, filed on Aug. 20, 2001, (27) U.S.provisional patent application Ser. No. 60/317,985, filed on Sep. 6,2001, (28) U.S. provisional patent application Ser. No. 60/3318,386,filed on Sep. 10, 2001, (29) U.S. patent application Ser. No.09/969,922, filed on Oct. 3, 2001, (30) U.S. patent application Ser. No.10/016,467, filed on Dec. 10, 2001; (31) U.S. provisional patentapplication Ser. No. 60/343,674, filed on Dec. 27, 2001; (32) U.S.provisional patent application Ser. No. 60/346,309, filed on Jan. 7,2002; (33) U.S. provisional patent application Ser. No. 60/372,048,filed on Apr. 12, 2002; (34) U.S. provisional patent application Ser.No. 60/372,632, filed on Apr. 15, 2002; and (35) U.S. provisional patentapplication Ser. No. 60/380,147, filed on May 6, 2002, the disclosuresof which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

This invention relates generally to oil and gas exploration, and inparticular to forming and repairing wellbore casings to facilitate oiland gas exploration and production.

Conventionally, when a wellbore is created, a number of casings areinstalled in the borehole to prevent collapse of the borehole wall andto prevent undesired outflow of drilling fluid into the formation orinflow of fluid from the formation into the borehole. The borehole isdrilled in intervals whereby a casing which is to be installed in alower borehole interval is lowered through a previously installed casingof an upper borehole interval. As a consequence of this procedure thecasing of the lower interval is of smaller diameter than the casing ofthe upper interval. Thus, the casings are in a nested arrangement withcasing diameters decreasing in downward direction. Cement annuli areprovided between the outer surfaces of the casings and the borehole wallto seal the casings from the borehole wall. As a consequence of thisnested arrangement a relatively large borehole diameter is required atthe upper part of the wellbore. Such a large borehole diameter involvesincreased costs due to heavy casing handling equipment, large drill bitsand increased volumes of drilling fluid and drill cuttings. Moreover,increased drilling rig time is involved due to required cement pumping,cement hardening, required equipment changes due to large variations inhole diameters drilled in the course of the well, and the large volumeof cuttings drilled and removed.

The present invention is directed to overcoming one or more of thelimitations of the existing processes for forming and repairing wellborecasings.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a method of radiallyexpanding and plastically deforming at least a portion of an expandabletubular member is provided that includes positioning a resilient memberwithin the interior of the expandable tubular member, and compressingthe resilient member within the interior of the expandable tubularmember to radially expand and plastically deform a portion of theexpandable tubular member.

According to another aspect of the present invention, a system forradially expanding and plastically deforming at least a portion of anexpandable tubular member is provided that includes means forpositioning a resilient member within the interior of the expandabletubular member, and means for compressing the resilient member withinthe interior of the expandable tubular member to radially expand andplastically deform a portion of the expandable tubular member.

According to another aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a support member, a resilient membercoupled to the support member, and an actuator operably coupled to theresilient member for controllably compressing the resilient member tothereby radially expand and plastically deform the expandable tubularmember.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a fragmentary cross-sectional illustration of an exemplaryembodiment of an apparatus for radially expanding and plasticallydeforming a tubular member.

FIG. 1 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 1 a after compressing the resilient expansion member to radiallyexpand and plastically deform a portion of the expandable tubularmember.

FIG. 1 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 1 b after permitting the resilient expansion member to re-expandin the longitudinal direction.

FIG. 1 d is a fragmentary cross-sectional illustration of the apparatusof FIG. 1 c after removing the resilient expansion member from theexpandable tubular member.

FIG. 1 e is a fragmentary cross sectional illustration of the apparatusof FIG. 1 d after positioning an adjustable expansion cone within theradially expanded and plastically deformed portion of the expandabletubular member.

FIG. 1 f is a fragmentary cross-sectional illustration of the apparatusof FIG. 1 e after expanding the adjustable expansion cone within theradially expanded and plastically deformed portion of the expandabletubular member.

FIG. 1 g is a fragmentary cross sectional illustration of the apparatusof FIG. 1 f after displacing the adjustable expansion cone relative tothe expandable tubular member to radially expand and plastically deformat least a portion of the expandable tubular member.

FIG. 2 a is a fragmentary cross-sectional illustration of the apparatusof FIG. 1 a after being positioned within a preexisting structure.

FIG. 2 b is a fragmentary cross sectional of the apparatus of FIG. 2 aafter compressing the resilient expansion member to radially expand andplastically deform a portion of the expandable tubular member intointimate contact with the interior surface of the preexisting structure.

FIG. 2 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 2 b after permitting the resilient expansion member to re-expandin the longitudinal direction.

FIG. 2 d is a fragmentary cross-sectional illustration of the apparatusof FIG. 2 c after removing the resilient expansion member from theexpandable tubular member.

FIG. 2 e is a fragmentary cross sectional illustration of the apparatusof FIG. 2 d after positioning an adjustable expansion cone within theradially expanded and plastically deformed portion of the expandabletubular member.

FIG. 2 f is a fragmentary cross-sectional illustration of the apparatusof FIG. 2 e after expanding the adjustable expansion cone within theradially expanded and plastically deformed portion of the expandabletubular member.

FIG. 2 g is a fragmentary cross sectional illustration of the apparatusof FIG. 2 f after displacing the adjustable expansion cone relative tothe expandable tubular member to radially expand and plastically deformat least a portion of the expandable tubular member.

FIG. 3 is a fragmentary cross-sectional illustration of the radialexpansion and plastic deformation of the expandable tubular member ofFIG. 2 a at a plurality of discrete locations by repeating theoperational steps of FIGS. 2 a-2 c a plurality of times within thepreexisting structure.

FIG. 4 is a fragmentary cross sectional illustration of an alternativeembodiment of the apparatus of FIG. 1 a in which an adjustable expansioncone is provided below the resilient expansion member.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring to FIG. 1 a, a cylindrical member 10 that includes a flange 12at one end is positioned within a first tubular member 14 that defines apassage 16 for receiving and mating with the flange of the cylindricalmember. A second tubular member 18 that is received within and mateswith the passage 16 of the first tubular member 14 defines a passage 20that receives and mates with another end of the cylindrical member 10,and a third tubular member 22 that is also received within and mateswith the passage of the first tubular member defines a passage 24 thatreceives and mates with an intermediate portion of the cylindricalmember. In this manner, the third tubular member 22 is positionedbetween an end face of the second tubular member 18 and an end face ofthe flange 12 of the cylindrical member 10. An actuator 25 is operablycoupled to the second tubular member 18 for controllably displacing thesecond tubular member relative to the cylindrical member 10 in thelongitudinal direction. In an exemplary embodiment, the cylindricalmember 10, the first tubular member 14, and the second tubular member 18are fabricated from rigid materials such as, for example, aluminum orsteel, and the third tubular member 22 is fabricated from resilientmaterials such as, for example, natural rubber, synthetic rubber, and/oran elastomeric material.

In an exemplary embodiment, as illustrated in FIG. 1 b, the secondtubular member 18 is then displaced downwardly in the longitudinaldirection toward the flange 12 of the cylindrical member 10 by theactuator 25. As a result, the resilient third tubular member 22 iscompressed in the longitudinal direction and expanded in the radialdirection thereby radially expanding and plastically deforming theportion 26 of the first tubular member 14 proximate the radiallyexpanded portion of the third tubular member 22. In an experimentalimplementation, the inside diameter of the portion 26 of the firsttubular member 14 proximate the radially expanded portion of the thirdresilient tubular member 22 was unexpectedly increased by up to about 22percent.

In an exemplary embodiment, as illustrated in FIG. 1 c, the secondtubular member 18 is then displaced upwardly in the longitudinaldirection away from the flange 12 of the cylindrical member 10 by theactuator 25. As a result, the resilient third tubular member 22 is nolonger compressed in the longitudinal direction or expanded in theradial direction. As a result, as illustrated in FIG. 1 d, thecylindrical member 10, the second tubular member 18, and the thirdtubular member 22 may then be removed from the passage 16 of the firsttubular member 14.

In an exemplary embodiment, as illustrated in FIG. 1 e, an adjustableexpansion cone 28 is then positioned within the radially expandedportion 26 of the first tubular member 14 using a support member 30.

In an exemplary embodiment, as illustrated in FIG. 1 f, the outsidediameter of the adjustable expansion cone 28 is then increased to matewith the inside surface of at least a portion of the radially expandedportion 26 of the first tubular member 14. The adjustable expansion cone28 is then displaced upwardly relative to the first tubular member 14.In several alternative embodiments, the adjustable expansion cone 28 isdisplaced upwardly relative to the first tubular member 14 by pullingthe adjustable expansion cone 28 upwardly and/or by pressurizing theregion 32 of the first tubular member below the adjustable expansioncone. In an exemplary embodiment, as illustrated in FIG. 1 g, as aresult of the upward displacement of the adjustable expansion cone 28relative to the first tubular member 14, an upper portion 34 of thefirst tubular member is radially expanded and plastically deformed.

In several exemplary embodiments, the upper portion 34 of the firsttubular member 14 is radially expanded and plastically deformed usingthe adjustable expansion cone 28 in a conventional manner and/or usingone or more of the methods and apparatus disclosed in one or more of thefollowing: (1) U.S. patent application Ser. No. 09/454,139, filed onDec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed onFeb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed onFeb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed onNov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed onMar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed onFeb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed onFeb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed onJun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed onApr. 26, 2000, (10) PCT patent application Ser. No. PCT/US00/18635,filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No.60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patentapplication Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S.provisional patent application Ser. No. 60/159,082, filed on Oct. 12,1999, (14) U.S. provisional patent application Ser. No. 60/159,039,filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser.No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patentapplication Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S.provisional patent application Ser. No. 60/165,228, filed on Nov. 12,1999, (18) U.S. provisional patent application Ser. No. 60/221,443,filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser.No. 60/221,645, filed on Jul. 28, 2000, (20) U.S. provisional patentapplication Ser. No. 60/233,638, filed on Sep. 18, 2000, (21) U.S.provisional patent application Ser. No. 60/237,334, filed on Oct. 2,2000, (22) U.S. provisional patent application Ser. No. 60/270,007,filed on Feb. 20, 2001, (23) U.S. provisional patent application Ser.No. 60/262,434, filed on Jan. 17, 2001, (24) U.S, provisional patentapplication Ser. No. 60/259,486, filed on Jan. 3, 2001, (25) U.S.provisional patent application Ser. No. 60/303,740, filed on Jul. 6,2001, (26) U.S. provisional patent application Ser. No. 60/313,453,filed on Aug. 20, 2001, (27) U.S. provisional patent application Ser.No. 60/317,985, filed on Sep. 6, 2001, (28) U.S. provisional patentapplication Ser. No. 60/3318,386, filed on Sep. 10, 2001, (29) U.S.patent application Ser. No. 09/969,922, filed on Oct. 3, 2001, (30) U.S.patent application Ser. No. 10/016,467, filed on Dec. 10, 2001; (31)U.S. provisional patent application Ser. No. 60/343,674, filed on Dec.27, 2001; (32) U.S. provisional patent application Ser. No. 60/346,309,filed on Jan. 7, 2002; (33) U.S. provisional patent application Ser. No.60/372,048, filed on Apr. 12, 2002; (34) U.S. provisional patentapplication Ser. No. 60/372,632, filed on Apr. 15, 2002; and (35) U.S.provisional patent application Ser. No. 60/380,147, filed on May 6,2002, the disclosures of which are incorporated herein by reference.

In several alternative embodiments, the upper portion 34 of the firsttubular member 14 is radially expanded and plastically deformed usingother conventional methods for radially expanding and plasticallydeforming tubular members such as, for example, internal pressurizationand/or roller expansion devices such as, for example, that disclosed inU.S. patent application publication no. US 2001/0045284 A1, thedisclosure of which is incorporated herein by reference.

In several alternative embodiments, the lower portion 36 of the firsttubular member 14 is radially expanded and plastically deformed insteadof, or in addition to, the upper portion 34.

Referring to FIG. 2 a, in an alternative embodiment, the cylindricalmember 10, the first tubular member 14, the second tubular member 18,and the third tubular member 22 are positioned within the interior of apreexisting structure 38. In several exemplary embodiments, thepreexisting structure 38 may be a wellbore, a wellbore casing, apipeline, or a structural support.

In an exemplary embodiment, as illustrated in FIG. 2 b, the secondtubular member 18 is then displaced downwardly in the longitudinaldirection toward the flange 12 of the cylindrical member 10 using theactuator 25. As a result, the resilient third tubular member 22 iscompressed in the longitudinal direction and expanded in the radialdirection thereby radially expanding and plastically deforming theportion 26 of the first tubular member 14 proximate the radiallyexpanded portion of the third tubular member 22 into intimate contactwith the interior surface of the preexisting structure 38. In anexperimental implementation, the inside diameter of the portion 26 ofthe first tubular member 14 proximate the radially expanded portion ofthe third resilient tubular member 22 was unexpectedly increased by upto about 22 percent. In an experimental implementation, the contactpressure between the radially expanded and plastically deformed portion26 of the first tubular member 14 and the interior surface of thepreexisting structure 38 provided a fluid tight seal and supported thefirst tubular member.

In an exemplary embodiment, as illustrated in FIG. 2 c, the secondtubular member 18 is then displaced upwardly in the longitudinaldirection away from the flange 12 of the cylindrical member 10 using theactuator 25. As a result, the resilient third tubular member 22 is nolonger compressed in the longitudinal direction or expanded in theradial direction. As a result, as illustrated in FIG. 2 d, thecylindrical member 10, the second tubular member 18, and the thirdtubular member 22 may then be removed from the passage 16 of the firsttubular member 14.

In an exemplary embodiment, as illustrated in FIG. 2 e, an adjustableexpansion cone 28 is then positioned within the radially expandedportion 26 of the first tubular member 14 using a support member 30.

In an exemplary embodiment, as illustrated in FIG. 2 f, the outsidediameter of the adjustable expansion cone 28 is then increased to matewith the inside surface of at least a portion of the radially expandedportion 26 of the first tubular member 14. The adjustable expansion cone28 is then displaced upwardly relative to the first tubular member 14.In several alternative embodiments, the adjustable expansion cone 28 isdisplaced upwardly relative to the first tubular member 14 by pullingthe adjustable expansion cone 28 upwardly and/or by pressurizing theregion 32 of the first tubular member below the adjustable expansioncone. In an exemplary embodiment, as illustrated in FIG. 2 g, as aresult of the upward displacement of the adjustable expansion cone 28relative to the first tubular member 14, an upper portion 34 of thefirst tubular member is radially expanded and plastically deformed. Inan exemplary experimental implementation, the upward displacement of theadjustable expansion cone 28 relative to the first tubular member 14,caused the upper portion 34 of the first tubular member to be radiallyexpanded and plastically deformed into intimate contact with theinterior surface of the preexisting structure.

In an alternative embodiment, as illustrated in FIG. 3, the firsttubular member 14 is radially expanded and plastically deformed intointimate contact with the preexisting structure 38 at a plurality ofspaced apart locations by operating the cylindrical member 10, the firsttubular member 14, the second tubular member 18, and the third tubularmember 22 a plurality of times as described above with reference toFIGS. 2 a-2 c. As a result, radially expanded and plastically deformedportions, 26 a and 26 b, of the first tubular member 14 are therebyradially expanded and plastically deformed into intimate contact withinterior surface of the preexisting structure 38. In an exemplaryexperimental implementation, the radially expanded and plasticallydeformed portions, 26 a and 26 b, of the first tubular member 14provided a fluid tight seal between the radially expanded portions andthe interior surface of the preexisting structure 38. In an exemplaryembodiment, the intermediate portion 40 of the first tubular member 14,positioned between the radially expanded and plastically deformedportions, 26 a and 26 b, of the first tubular member, includes one ormore openings, slots, and/or apertures 44 for conveying fluidicmaterials into and/or out of the first tubular member. In this manner,fluidic materials within a subterranean formation 42 positionedproximate the intermediate portion may be extracted into the interior 16of the first tubular member. Or, alternatively, fluidic materials may beinjected into the subterranean formation. In several alternativeembodiments, the subterranean formation 42 may include a source ofhydrocarbons such as, for example, petroleum and/or natural gas, and/ora source of geothermal energy.

In an alternative embodiments, as illustrated in FIG. 4, an adjustableexpansion cone 42 is coupled to the cylindrical member 10 below theresilient third tubular member 22. In this manner, during operation,after expanding the resilient tubular member 22 in the radial directionto thereby radially expand and plastically deform the first tubularmember 14, the adjustable expansion cone 42 may then be positionedproximate the radially expanded portion of the first tubular member andradially expanded. The adjustable expansion cone 42 may then bedisplaced upwardly and/or downwardly relative to the first tubularmember 14 in the longitudinal direction to thereby radially expand andplastically deform at least a portion of the first tubular member.

A method of radially expanding and plastically deforming at least aportion of an expandable tubular member has been described that includespositioning a resilient member within the interior of the expandabletubular member, and compressing the resilient member within the interiorof the expandable tubular member to radially expand and plasticallydeform a portion of the expandable tubular member. In an exemplaryembodiment, the inside diameter of the radially expanded portion of theexpandable tubular member is increased by up to about 22 percent duringthe radial expansion and plastic deformation. In an exemplaryembodiment, the method further includes positioning an adjustableexpansion cone within the radially expanded and plastically deformedportion of the expandable tubular member, expanding the adjustableexpansion cone within the radially expanded and plastically deformedportion of the expandable tubular member, and displacing the adjustableexpansion cone relative to the expandable tubular member in thelongitudinal direction to radially expand and plastically deform anotherportion of the expandable tubular member. In an exemplary embodiment,the method further includes decompressing the resilient member withinthe interior of the expandable tubular member, positioning the resilientmember to another location within the interior of the expandable tubularmember, and compressing the resilient member within the interior of theexpandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member. In an exemplaryembodiment, the method further includes positioning the expandabletubular member within a preexisting structure. In an exemplaryembodiment, the preexisting structure includes a wellbore. In anexemplary embodiment, the preexisting structure includes a wellborecasing. In an exemplary embodiment, the preexisting structure includes apipeline. In an exemplary embodiment, the preexisting structure includesa structural support. In an exemplary embodiment, the method furtherincludes compressing the resilient member within the interior of theexpandable tubular member to radially expand and plastically deform aportion of the expandable tubular member into contact with the interiorsurface of the preexisting structure. In an exemplary embodiment, themethod further includes decompressing the resilient member within theinterior of the expandable tubular member, positioning the resilientmember to another location within the interior of the expandable tubularmember, and compressing the resilient member within the interior of theexpandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member into contact with theinterior surface of the preexisting structure. In an exemplaryembodiment, the intermediate portion of the expandable tubular memberpositioned between the radially expanded and plastically deformedportions defines one or more radial openings for conveying fluidicmaterials between the interiors of the expandable tubular member and thepreexisting structure. In an exemplary embodiment, the preexistingstructure includes a wellbore that traverses a subterranean formation.In an exemplary embodiment, the subterranean formation includes a sourceof geothermal energy. In an exemplary embodiment, the subterraneanformation includes a source of hydrocarbons. In an exemplary embodiment,the method further includes compressing the resilient member in thelongitudinal direction within the interior of the expandable tubularmember to radially expand and plastically deform a portion of theexpandable tubular member. In an exemplary embodiment, the resilientmember is a resilient tubular member. In an exemplary embodiment, theexpandable tubular member is a solid expandable tubular member. In anexemplary embodiment, the expandable tubular member defines one or moreradial openings for conveying fluidic materials.

A system for radially expanding and plastically deforming at least aportion of an expandable tubular member has been described that includesmeans for positioning a resilient member within the interior of theexpandable tubular member, and means for compressing the resilientmember within the interior of the expandable tubular member to radiallyexpand and plastically deform a portion of the expandable tubularmember. In an exemplary embodiment, the inside diameter of the radiallyexpanded portion of the expandable tubular member is increased by up toabout 22 percent during the radial expansion and plastic deformation. Inan exemplary embodiment, the system further includes means forpositioning an adjustable expansion cone within the radially expandedand plastically deformed portion of the expandable tubular member, meansfor expanding the adjustable expansion cone within the radially expandedand plastically deformed portion of the expandable tubular member, andmeans for displacing the adjustable expansion cone relative to theexpandable tubular member in the longitudinal direction to radiallyexpand and plastically deform another portion of the expandable tubularmember. In an exemplary embodiment, the system further includes meansfor decompressing the resilient member within the interior of theexpandable tubular member, means for positioning the resilient member toanother location within the interior of the expandable tubular member,and means for compressing the resilient member within the interior ofthe expandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member. In an exemplaryembodiment, the system further includes means for positioning theexpandable tubular member within a preexisting structure. In anexemplary embodiment, the preexisting structure includes a wellbore. Inan exemplary embodiment, the preexisting structure includes a wellborecasing. In an exemplary embodiment, the preexisting structure includes apipeline. In an exemplary embodiment, the preexisting structure includesa structural support. In an exemplary embodiment, the system furtherincludes means for compressing the resilient member within the interiorof the expandable tubular member to radially expand and plasticallydeform a portion of the expandable tubular member into contact with theinterior surface of the preexisting structure. In an exemplaryembodiment, the system further includes means for decompressing theresilient member within the interior of the expandable tubular member,means for positioning the resilient member to another location withinthe interior of the expandable tubular member, and means for compressingthe resilient member within the interior of the expandable tubularmember to radially expand and plastically deform another portion of theexpandable tubular member into contact with the interior surface of thepreexisting structure. In an exemplary embodiment, an intermediateportion of the expandable tubular member positioned between the radiallyexpanded and plastically deformed portions defines one or more radialopenings for conveying fluidic materials between the interiors of theexpandable tubular member and the preexisting structure. In an exemplaryembodiment, the preexisting structure includes a wellbore that traversesa subterranean formation. In an exemplary embodiment, the subterraneanformation includes a source of geothermal energy. In an exemplaryembodiment, the subterranean formation includes a source ofhydrocarbons. In an exemplary embodiment, the system further includesmeans for compressing the resilient member in the longitudinal directionwithin the interior of the expandable tubular member to radially expandand plastically deform a portion of the expandable tubular member. In anexemplary embodiment, the resilient member includes a resilient tubularmember. In an exemplary embodiment, the expandable tubular member is asolid expandable tubular member. In an exemplary embodiment, theexpandable tubular member defines one or more radial openings forconveying fluidic materials.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes a supportmember, a resilient member coupled to the support member, and anactuator operably coupled to the resilient member for controllablycompressing the resilient member to thereby radially expand andplastically deform the expandable tubular member. In an exemplaryembodiment, the resilient member includes a tubular resilient member. Inan exemplary embodiment, the apparatus further includes an adjustableexpansion cone coupled to the support member. In an exemplaryembodiment, the actuator is adapted to compress the resilient member inthe longitudinal direction and thereby cause the resilient member toexpand in the radial direction. In an exemplary embodiment, the supportmember is fabricated from a rigid material. In an exemplary embodiment,the rigid material is selected from the group consisting of steel andaluminum. In an exemplary embodiment, the resilient member is fabricatedfrom materials selected from the group consisting of natural rubber,synthetic rubber, and elastomeric material.

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the invention. For example, the teachings ofthe present illustrative embodiments may be used to provide a wellborecasing, a pipeline, or a structural support. Furthermore, the elementsand teachings of the various illustrative embodiments may be combined inwhole or in part in some or all of the illustrative embodiments.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1. A method of radially expanding and plastically deform ing at least aportion of an expandable tubular member, comprising: positioning aresilient member within the interior of the expandable tubular member;compressing the resilient member within the interior of the expandabletubular member to radially expand and plastically deform a portion ofthe expandable tubular member; positioning an adjustable expansiondevice within the radially expanded and plastically deformed portion ofthe expandable tubular member; expanding the adjustable expansion devicewithin the radially expanded and plastically deformed portion of theexpandable tubular member; and displacing the adjustable expansiondevice relative to the expandable tubular member in the longitudinaldirection to radially expand and plastically deform another portion ofthe expandable tubular member.
 2. The method of claim 1, wherein theinside diameter of the radially expanded portion of the expandabletubular member is increased by up to about 22 percent during the radialexpansion and plastic deformation.
 3. The method of claim 1, wherein theinside diameter of the radially expanded portion of the expandabletubular member is increased by up to about 11 percent during the radialexpansion and plastic deformation.
 4. The method of claim 1, furthercomprising: decompressing the resilient member within the interior ofthe expandable tubular member; positioning the resilient member toanother location within the interior of the expandable tubular member;and compressing the resilient member within the interior of theexpandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member.
 5. The method of claim1, further comprising: positioning the expandable tubular member withina preexisting structure.
 6. The method of claim 5, wherein thepreexisting structure comprises a wellbore.
 7. The method of claim 5,wherein the preexisting structure comprises a wellbore casing.
 8. Themethod of claim 5, wherein the preexisting structure comprises apipeline.
 9. The method of claim 5, wherein the preexisting structurecomprises a structural support.
 10. The method of claim 5, furthercomprising: compressing the resilient member within the interior of theexpandable tubular member to radially expand and plastically deform aportion of the expandable tubular member into contact with the interiorsurface of the preexisting structure.
 11. The method of claim 10,further comprising: decompressing the resilient member within theinterior of the expandable tubular member; positioning the resilientmember to another location within the interior of the expandable tubularmember; and compressing the resilient member within the interior of theexpandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member into contact with theinterior surface of the preexisting structure.
 12. The method of claim11, wherein an intermediate portion of the expandable tubular memberpositioned between the radially expanded and plastically deformedportions defines one or more radial openings for conveying flu idicmaterials between the interiors of the expandable tubular member and thepreexisting structure.
 13. The method of claim 12, wherein thepreexisting structure comprises a wellbore that traverses a subterraneanformation.
 14. The method of claim 13, wherein the subterraneanformation comprises a source of geothermal energy.
 15. The method ofclaim 13, wherein the subterranean formation comprises a source ofhydrocarbons.
 16. The method of claim 1, further comprising: compressingthe resilient member in the longitudinal direction within the interiorof the expandable tubular member to radially expand and plasticallydeform a portion of the expandable tubular member.
 17. The method ofclaim 1, wherein the resilient member comprises a resilient tubularmember.
 18. The method of claim 1, wherein the expandable tubular membercomprises a solid expandable tubular member.
 19. The method of claim 1,wherein the expandable tubular member defines one or more radialopenings for conveying fluidic materials.
 20. A system for radiallyexpanding and plastically deforming at least a portion of an expandabletubular member, comprising: means for positioning a resilient memberwithin the interior of the expandable tubular member; means forcompressing the resilient member within the interior of the expandabletubular member to radially expand and plastically deform a portion ofthe expandable tubular member; means for positioning an adjustableexpansion device within the radially expanded and plastically deformedportion of the expandable tubular member; means for expanding theadjustable expansion device within the radially expanded and plasticallydeformed portion of the expandable tubular member; and means fordisplacing the adjustable expansion device relative to the expandabletubular member in the longitudinal direction to radially expand andplastically deform another portion of the expandable tubular member. 21.The system of claim 20, wherein the inside diameter of the radiallyexpanded portion of the expandable tubular member is increased by up toabout 22 percent during the radial expansion and plastic deformation.22. The system of claim 20, wherein the inside diameter of the radiallyexpanded portion of the expandable tubular member is increased by up toabout 11 percent during the radial expansion and plastic deformation.23. The system of claim 20, further comprising: means for decompressingthe resilient member within the interior of the expandable tubularmember; means for positioning the resilient member to another locationwithin the interior of the expandable tubular member; and means forcompressing the resilient member within the interior of the expandabletubular member to radially expand and plastically deform another portionof the expandable tubular member.
 24. The system of claim 20, furthercomprising: means for positioning the expandable tubular member within apreexisting structure.
 25. The system of claim 24, wherein thepreexisting structure comprises a wellbore.
 26. The system of claim 24,wherein the preexisting structure comprises a wellbore casing.
 27. Thesystem of claim 24, wherein the preexisting structure comprises apipeline.
 28. The system of claim 24, wherein the preexisting structurecomprises a structural support.
 29. The system of claim 24, furthercomprising: means for compressing the resilient member within theinterior of the expandable tubular member to radially expand andplastically deform a portion of the expandable tubular member intocontact with the interior surface of the preexisting structure.
 30. Thesystem of claim 29, further comprising: means for decompressing theresilient member within the interior of the expandable tubular member;means for positioning the resilient member to another location withinthe interior of the expandable tubular member; and means for compressingthe resilient member within the interior of the expandable tubularmember to radially expand and plastically deform another portion of theexpandable tubular member into contact with the interior surface of thepreexisting structure.
 31. The system of claim 30, wherein anintermediate portion of the expandable tubular member positioned betweenthe radially expanded and plastically deformed portions defines one ormore radial openings for conveying fluidic materials between theinteriors of the expandable tubular member and the preexistingstructure.
 32. The system of claim 31, wherein the preexisting structurecomprises a wellbore that traverses a subterranean formation.
 33. Thesystem of claim 32, wherein the subterranean formation comprises asource of geothermal energy.
 34. The system of claim 32, wherein thesubterranean formation comprises a source of hydrocarbons.
 35. Thesystem of claim 20, further comprising: means for compressing theresilient member in the longitudinal direction within the interior ofthe expandable tubular member to radially expand and plastically deforma portion of the expandable tubular member.
 36. The system of claim 20,wherein the resilient member comprises a resilient tubular member. 37.The system of claim 20, wherein the expandable tubular member comprisesa solid expandable tubular member.
 38. The system of claim 20, whereinthe expandable tubular member defines one or more radial openings forconveying fluidic materials.
 39. A method of recovering materials from asubterranean zone, comprising: positioning an expandable tubular memberthat defines one or more radial passages within a wellbore thattraverses the subterranean zone; positioning a resilient member withinthe interior of the expandable tubular member; compressing the resilientmember within the interior of the expandable tubular member to radiallyexpand and plastically deform a first portion of the expandable tubularmember; decompressing the resilient member within the interior of theexpandable tubular member; positioning the resilient member to anotherlocation within the interior of the expandable tubular member;compressing the resilient member within the interior of the expandabletubular member to radially expand and plastically deform a secondportion of the expandable tubular member; and recovering materials fromthe subterranean zone through one or more of the radial passages of theexpandable tubular member; wherein the first and second portions of theexpandable tubular member are spaced apart from one another.
 40. Themethod of claim 39, wherein the radial passages of the expandabletubular member are defined between the first and second portions of theexpandable tubular member.
 41. The method of claim 39, wherein thematerials comprise hydrocarbons.
 42. The method of claim 39, wherein thematerials comprise geothermal energy.
 43. The method of claim 39,wherein an annulus defined between the portion of the expandable tubularmember between the first and second portions of the expandable tubularmember and the wellbore is fluidicly isolated from another annulusdefined between the expandable tubular member and the wellbore.
 44. Asystem for recovering materials from a subterranean zone, comprising:means for positioning an expandable tubular member that defines one ormore radial passages within a wellbore that traverses the subterraneanzone; means for positioning a resilient member within the interior ofthe expandable tubular member; means for compressing the resilientmember within the interior of the expandable tubular member to radiallyexpand and plastically deform a first portion of the expandable tubularmember; means for decompressing the resilient member within the interiorof the expandable tubular member; means for positioning the resilientmember to another location within the interior of the expandable tubularmember; means for compressing the resilient member within the interiorof the expandable tubular member to radially expand and plasticallydeform a second portion of the expandable tubular member; and means forrecovering materials from the subterranean zone through one or more ofthe radial passages of the expandable tubular member; wherein the firstand second portions of the expandable tubular member are spaced apartfrom one another.
 45. The system of claim 44, wherein the radialpassages of the expandable tubular member are positioned between thefirst and second portions of the expandable tubular member.
 46. Thesystem of claim 44, wherein the materials comprise hydrocarbons.
 47. Thesystem of claim 44, wherein the materials comprise geothermal energy.